Conical Compression Limiters for Battery Array Structural Integrity
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Solution Overview
Problem
The challenge in battery assemblies for electrified vehicles is securing multiple battery arrays within a confined space while maintaining structural integrity and simplifying assembly and handling, as conventional methods often require accessing tight spaces and complex fastening procedures.
Innovation Solution
The implementation of conical-shaped compression limiters with an attachment head and flange, which engage structural members like side walls of the battery arrays, guiding fasteners to a tray for secure mounting and compressive load distribution, facilitating a 'top-down' attachment technique that simplifies assembly and improves access to tight spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fastening methods are used to secure battery arrays, then structural integrity is maintained, but assembly complexity increases and access to tight spaces is required
Solution Approach 1:
The compression limiter serves as an intermediary component between the support structure and battery arrays, providing a simplified fastening interface that eliminates the need for complex conventional fastening procedures while maintaining structural integrity through controlled compression
Solution Approach 2:
The compression limiter automatically maintains proper compression force on the battery arrays through its elastic properties, eliminating the need for additional adjustment mechanisms or complex fastening procedures while ensuring continuous structural integrity
2Reliability
If conventional fastening methods are used to secure battery arrays, then structural integrity is maintained, but ease of operation deteriorates due to difficulty accessing tight spaces
Solution Approach 1:
The compression limiter acts as a mediator that transforms the fastening operation into a simpler process by providing an accessible interface on the outer surface of the support structure, allowing assembly operations to be performed without accessing tight internal spaces while still securing the battery arrays effectively
3Ease of operation
If compression limiters are used to secure battery arrays, then ease of assembly improves, but device complexity increases due to additional components
Solution Approach 1:
The compression limiter performs multiple functions simultaneously: it secures battery arrays, maintains compression force, guides fastener installation, and provides structural support integration, thereby simplifying the overall device architecture despite adding a component with multifunctional capabilities
Data Source
AI summary
This disclosure details battery assemblies for electrified vehicles. An exemplary battery assembly may employ one or more compression limiters that maintain the integrity and positioning of a plurality of battery arrays housed inside the battery assembly. The compression limiters may include a body and an attachment head near an end of the body. The attachment head is configured to engage a portion of a support structure of a battery array.